Peugeot Innovation 44% of vehicles on the world's roads are fitted with an automatic gearbox.With its AL4 gearbox, Peugeot is anticipating the growth in this market. Compact and lightweight (70 kg), it is virtually maintenance-free and provides operating modes suited to the motorist's driving style, giving the same driving sensations as a manual gearbox.HOW DOES IT WORK ? The mechanismThe mechanism of the AL4 consists of two 2 single epicyclic gear trains coupled together.These gear trains are made up of 3 types of freely rotating elements : a ring wheel three planet wheels a sun wheel.The different transmission ratios (4 gears and reverse) are obtained by blocking of one of the elements of each train and locking of one of the elements with the input shaft which delivers the engine torque.These actions are carried out with the help of clutches and brakes (lubricated and maintenance-free).The pump, driven by the engine, delivers the hydraulic power necessary to actuate the clutches and brakes.The hydraulic distributor, which is the interface between the computer and the mechanism, incorporates the elements necessary for the oil regulation and distribution functions. It acts on the brakes and clutches, and supplies the greasing and cooling systems and the converter.The gears and the coupling transmit the movement between the mechanism and the wheels. The gearing is adapted to the associated engine.The electronic computer decides on the gear changes according to the vehicle's speed, the engine speed and the position of the selector lever. Using preset gear change rules, the computer chooses the gears which correspond to the behaviour of the driver and to external factors such as the oil temperature, the slope of the road or the vehicle load. It also transmits commands to the hydraulic circuit.The torque converter transmits the movement of the engine to the gearbox via a hydraulic connection. It replaces the mechanical clutch of a manual gearbox. Its hydraulic operation provides greater flexibility of use. Moreover, a coupling device provides a direct mechanical connection which takes the place of the converter to optimise the efficiency of the gearbox.See the diagramAL4 mechanismFACILITIES http://www.peugeot.com/innovation/en/conf_boite_tec.htm (1 of 2)2548-12-03 20:28:34http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htmB2CI05K1 - 206 AL4 AUTOMATIC GEARBOX DRAINING/REFILLING/CHECK OF LEVEL OIL 1 - FOREWORD The (AL4) autoadaptive automatic gearbox is lubricated for life .All that is required is an oil level check at 60000 km .Despite that, the automatic gearbox has a system for measuring oil quality .The AL4 autoadaptive automatic gearbox ECU has an oil wear sensor .For a given time interval, the counter increases by a certain number of units (of wear) depending on the temperature of the gearbox .When the counter is exhausted, the gearbox ECU informs the driver of the presence of a fault by the flashing of the Sport and Snow indicator lights on the instrument panel .Using the diagnostic equipment, the technician checks whether or not it is necessary to replace the gearbox oil .For any operation requiring a top-up of at least 0,5 litre(s) of gearbox oil, update the oil wear counter by using the diagnostic equipment .IMPERATIVE : in the case of an automatic gearbox oil change, following flashing of the Sport and Snow indicator lights with a message on the diagnostic equipment: Oil Change to be Carried Out = Yes + counter exhausted at units, fill in the automatic gearbox form ; see SERVICE INFORMATION(s) : repair procedure BVA 4HP20 / AL4 / MB3 number 425 and 399 .2 - DRAINING NOTE : gearbox in place ; partial oil change; about 4 litre(s) are removed .http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm (1 of 5)2548-12-10 16:23:39http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm Gearbox oil warm : Remove the bolt (1) (6 sides of 27 mm) .3 - REFILLING IMPERATIVE : use only ESSO LT 71141 fluid .http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm (2 of 5)2548-12-10 16:23:39http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm REMOVE THE CAP (2) USING THE TOOL [23] .IMPERATIVE : do not remove the bolt (3) .FILL THE GEARBOX USING THE EQUIPMENT [22] .Quantity of oil to use :q after draining and refilling : 4 litre(s) q after removal/refitting of hydraulic block housing : 1,5 litre(s) q after draining and replacement of hydraulic block : 4,5 litre(s) q after draining and replacement of converter : 5 litre(s) IMPERATIVE : for any operation requiring a top-up of at least 0,5 litre(s) of gearbox oil, update the oil wear counter by using the diagnostic equipment ; follow the oil level checking procedure .4 - CHECK IMPERATIVE : use only fluid ESSO LT 71141 .http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm (3 of 5)2548-12-10 16:23:39http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm4 - 1 - PRIOR CONDITIONS Check absence of faults using the diagnostic equipment .Place the vehicle on a four-post lift .Gear lever in position P (Without handbrake) .Connect the diagnostic equipment .Select the parameter measurement function . Remove the filler plug (2) .IMPERATIVE : ADD 0,5 LITRE(S) OF OIL USING THE EQUIPMENT [22] .WARNING : do not remove the bolt (3) .Engine running : Warm the gearbox oil to a temperature between 58 C and 68 C .http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm (4 of 5)2548-12-10 16:23:39http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm Engine running : Remove the oil level plug (4) (6 sides of 19 mm) .The oil runs in a trickle then drips, the level is correct .IMPERATIVE : updating the oil wear counter .The oil drips or does not flow at all :q stop the engine q allow it to cool q add 0,5 litre(s) of oil q start the operation again q always renew : the seal q tighten the bolt (4) to 2,4 da.Nm IMPERATIVE : it is essential to add 0,5 litre(s) of oil before carrying out the procedure .http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b2ci05k3.htm (5 of 5)2548-12-10 16:23:39 www.VlovePeugeot.com - Please Ctrl+D Bookmark Now! VlovePeugeot.com Webboard multi function switch auto multi function switch auto 406 d8 ea9 switch , peugeot : - ICQ : - [ 3 .. 2546 , 20:41:57 . ] 0 406 ( air senser ) multi function switch 0 0 0 : pom406 - pom406 [ 4 .. 2546 , 11:10:04 .] To help filter out vibration and noise, the gear selection and gear changing countershafts are now (each) fitted with a counter balance weight of almost 500 gm. : - [ 6 .. 2546 , 06:58:22 .] .... http://www.tehama.com.ye/peugot-406-st-hi.htm -To help filter out vibration and noise, the gear selection and gear changing countershafts are now (each) fitted with a counter balance weight of almost 500 gm. -On all models with a engine version as well as on the six-cylinder models, the clutch control is hydraulic with a pull mechanism on the ML gearboxes and a push mechanism on the BE4 gearboxes. -The hydraulic transmitter is on the foot pedal assembly, which also incorporates a thrust stop ensuring a de-clutching action 25 mm from the end of travel. -There are few modifications to the 406's running gear. The car's suspension has been designed to fulfil two essential roles: outstanding roadholding and optimum passenger comfort : - [ 6 .. 2546 , 07:00:59 .] AL4 http://www.peugeot-avenue.com/innovation/en/conf_boite_tec.htm Auto Adatptive Gear Box The electronic computer decides on the gear changes according to the vehicle's speed, the engine speed and the position of the selector lever. Using preset gear change rules, the computer chooses the gears which correspond to the behaviour of the driver and to external factors such as the oil temperature, the slope of the road or the vehicle load. It also transmits commands to the hydraulic circuit. : - [ 6 .. 2546 , 07:10:35 .] Post message : * email : icq : Username : www.VlovePeugeot.com - Please Ctrl+D Bookmark Now! 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VlovePeugeot.com Webboard multi function switch switch : - ICQ : - [ 24 .. 2546 , 18:58:31 . ] switch 2 ( 1 ) switch (EA9 2 C5 1 ) (0.5-1.) switch : - [ 24 .. 2546 , 19:30:43 .] post + - delay programe software update 206 307 citroen C5 C8 C5 break 406 d8 turn C5 406 ea9 switch de thon switch 0 +- 5 ohm 0 ohm ECU , () ECU service diag 2000 standard switch post start standard multi function switch mechanic switch : - [ 24 .. 2546 , 20:09:38 .] .... 306 : foxII - foxII [ 24 .. 2546 , 20:28:00 .] 306 : [505man] - [ 24 .. 2546 , 21:23:11 .] 306 Peugeot 405 406 ea9 : Webmaster - Webmaster [ 24 .. 2546 , 22:11:18 .] : pom406 - pom406 [ 25 .. 2546 , 12:59:45 .] Post message : * email : icq : Username : Password : : ( 50K)Browse... www.VlovePeugeot.com - Please Ctrl+D Bookmark Now! .... VlovePeugeot.com Webboard Engine Break 406 Ohm Error 2 : Blue9 - ICQ : - [ 15 .. 2004 , 22:36:23 . ] 1 1 2 3000 2 automatic gear fault digital multi function switch 2 peugeot de thon : - [ 17 .. 2004 , 08:24:36 .] 2 : Blue9 [ 17 .. 2004 , 22:17:53 .] GeneralTransmissionsAL4 TransmissionSupply to sensors fault, 306Adjusting the manual valve.Adjusting the multifuncion switch.Output speed sensor fault.Pressure regulation fault.Multifunction Switch Fault.(307) Manually UnlockingThe Selector Lever http://www.peugeotlogic.com/workshop/base/navtran1.htm2548-12-08 1:32:54Supply faultSupply to sensors fault. No supply.Created: 01. 10. 2005Updated: --. --. ---- Model: 306 N5 with XU10J4R (2.0 litre) engine, AL4 automatic transmission. Symptomsq The transmission is in limp-home modeq Sport and winter lights flashingq Transmission ECU fault code present. Permanent fault, sensors supply.q No current supplied to fluid pressure and temperature sensors. (should be 5V) Initial checksIn parameters check engine load. If the engine load is at a constant 88% in the foot off position, check the TPS, the connector and the wiring between the ECU and the Throttle Position Switch.The engine load in the foot off position is 6%, in the full throttle position 88%. If there is no change with throttle movement, check the TPS. RectificationThe TPS was at fault. Replaced TPS. General sensor informationThe TPS sensor for the automatic transmission is a rheostat type and is housed in the same casing as the TPS for the fuel management system, it is mounted on the lower side of the throttle body. The transmission sensor can be identified by the blue 3-way connector. Summary for this fault.In this particular case the problem was caused by a faulty TPS that was giving a permanent full throttle signal. This caused the transmission ECU to cut the supply to the sensors and go into limp-home mode. Diagnosis was somewhat difficult due to the fact that a fault code was generated that pointed in the direction of one of the symptoms and not the cause of the problem. After checking the fluid pressure and temperature sensor wiring and connections many times, it became clear that the transmission control unit was not supplying the current for the sensors. The suspicion turned now towards the ECU which was substituted without success. At this point it became clear that an input parameter had to cause the ECU to shut off the sensor supply. The only irregular known parameter was the engine load at a constant 88%. A quick wiggle on the blue TPS connector proved the theory. Once the throttle signal was back to normal, http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/supply.htm (1 of 3)2548-12-08 1:33:04Supply faultthe ECU restored the power supply to the sensors and the system returned to normal operation. Some basic testing information.1. Resistance across pin 1 and 2, 2k constant.2. Resistance across pin 1 and 3, 2.8k when spindle turned clockwise to full stop.3. Resistance across pin 1 and 3, 1k when spindle turned counter clockwise to full stop.When turning the spindle of the throttle position sensor for the automatic transmission the resistance between pin 1 and pin 3 should change gradually in a smooth curve without any high or low resistance spikes. Throttle Position Sensorhttp://www.peugeotlogic.com/workshop/wshtml/transmis/al4/supply.htm (2 of 3)2548-12-08 1:33:04Supply faultTechnical information bypeugeotlogic.comhttp://www.peugeotlogic.com/workshop/wshtml/transmis/al4/supply.htm (3 of 3)2548-12-08 1:33:04Speed SensorAL4 Transmission output speed sensor faultCr eat ed: 23. 09. 2005Updat ed: - - . - - . - - - - Model206, 306, 307, 406 wit h AL4 aut omat ic t ransmission. Sy m pt om sWit h an out put speed sensor malfunct ion t he following sympt oms can be experienced. q "S" and "W" light flashing,or "Aut omat ic Transmission Fault " on display.q Unt imely gearshift s.q Harsh up and down shift s.q Hanging in gear.q Thumping aft er st opping. Rect i f i cat i onCheck sensor connect ions. I f connect ions OK, replace t he sensor. Gener al sensor i nf or m at i onThe out put speed sensor is mount ed below t he 33 way grey connect or at t he back of t he t ransmission case. I t is bolt ed t o t he housing from t he out side and reaches t hrough an opening in close proximit y of t he out put shaft . http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/sensor_a.htm (1 of 2)2548-12-08 1:33:29Speed SensorThe out put speed sensor is of t he induct ive t ype. I t generat es an AC signal and does not require a power supply. The sensor is t riggered by t he rot at ion of t he t ransmission' s out put shaft . The signal is sent t o pin 47 and 48 of t he t ransmission ECU connect or. Depending on t he model, t he sensor can be connect ed t o t he t ransmission wit h t he black 2 way connect or or t hrough t he grey 33 way connect or - E1 and E2- ( blue block) . The sensor resist ance should be bet ween 1000 and 1400. Technical informat ion bypeugeot logic. comhttp://www.peugeotlogic.com/workshop/wshtml/transmis/al4/sensor_a.htm (2 of 2)2548-12-08 1:33:29AL4 SolenoidsAL4 Pressure Regulation FaultCr eat ed: 27. 09. 2003Updat ed: 20. 09. 2005 Model : 206, 306, 307, 406 wit h AL4 Aut omat ic Transmission.Sy m pt om sFlashing of t he snow or sport s light or Aut omat ic Transmission Fault on display. I n most cases t he t ransmission will go int o t he downgraded mode, or limp home. I n t his mode t he t ransmission is locked in t hird speed t o enable t o cont inue t he operat ion of t he vehicle. This is report ed by some drivers as a loss of power. The downgraded mode can be preceded by some very harsh up or down shift s. Aft er st opping and rest art ing t he engine, t he t ransmission will usually ret urn t o normal operat ion. Most of t he t ime t he problem appears at unpredict able int ervals. Some owners experience incidences on a daily basis and ot hers may have weeks of t rouble free operat ion bet ween incident s. Normally t he malfunct ion last s only for short periods, from a few seconds t o a minut e or t wo. The following fault code is logged in t he t ransmission ECU:"I nt ermit t ent fault . Pressure regulat ion fault , recommendat ion/ variat ion" CauseThe pressure regulat ion fault code is t riggered when t he ECU senses a difference bet ween t he calculat ed pressure and t he act ual line pressure in t he t ransmission. The pressure difference is caused by int ernal leakage. I nt ernal leaks can be caused by mechanical wear, a leak bet ween valve body and t ransmission casing, incorrect adj ust ment of t he manual valve index spring. The most common cause however is t he pressure regulat ion solenoid valve. Di agnosi s.The diagnosis is not st raight forward, several operat ions are required t o eliminat e possibilit ies. 1. Tr ansm i ssi on f l ui da. Check t he fluid level in t he t ransmission and rect ify if as required. Low or high http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/solenoid.htm (1 of 4)2548-12-08 1:33:50AL4 Solenoidsfluid levels are equally harmfull. b. Save some of t he drained fluid in a clean cont ainer for examinat ion. The t ransmission may need t o be overhauled or replaced if:The fluid sample is black and smells burnt , cont ains met al part icles, plast ic part icles or frict ion mat erial.New fluid is t ransparent . Fluid drained from a t ransmission t hat has been in operat ion for some t ime is usually dark in colour and lacks t ransparency, t his is accept able and not necessarily an indicat ion of an int ernal fault . Caut ion is t o be exercised wit h t he fluid assessment . 2. Pr essur e sensora. Wit h help of t he diagnost ic comput er check t he t ransmission line pressure.The following paramet ers are expect ed.At idle in N: 2, 4 - 2, 8 bars.At idle in D: 2, 8 - 3, 1 bars.Under full load 2200 rpm: 11, 3 - 11, 7 bars. b. I f t here is no change in pressures, t est t he sensor and sensor supply. I f a sensor is fault y a const ant pressure of 6, 5 bars is maint ained by t he syst em. This would also mean t hat t he t ransmision would be in Limp Home Mode and t hat t he fault is permanent . Since t he problem usually is int ermit t ent t he pressure readings will check out OK most of t he t ime. I f no ot her problems have been found so far, cont inue wit h sect ion 3. 3. Sol enoi d Val ves a. Replace t he pressure regulat ion valve and t he convert er lock- up valves.b. Make sure t he 2 seals behind t he valve body are correct ly fit t ed. I f necessary replace t he seals.Tension t he valve body bolt s t o 8 NM.c. Aft er fit t ing t he valve body adj ust t he select or index springd. Adj ust t he mult i- funct ion swit ch.e. Before fit t ing t he pan ensure t he 2 magnet s are present . f. Fill t he t ransmission wit h new fluid and adj ust t he level.g. Updat e t he t ransmission ECU soft ware. The older soft ware versions are not compat ible wit h t he new Borg Warner valves.The operat ions aut lined obove will in most cases resolve t he pressure regulat ion problem. I f t he problem can' t be resolved follow st ep 4 or 5. 4. Val ve Bodya. Replace t he valve body5. Tr ansm i ssi ona. Replace or overhaul t he t ransmission.http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/solenoid.htm (2 of 4)2548-12-08 1:33:50AL4 SolenoidsPart No. For solenoid: 2574. 10 ( obsolet e) Part No. For new Borg Warner valves: 2574. 16 Part No. For set of magnet s: 2221. 17Part No. For t ransmission fluid. ( 2 lit res) : 9736. 22I m por t ant r em i nder s1. Only use genuine Peugeot t ransmission fluid.2. The fluid level must be correct .3. The correct adj ust ment of t he manual valve index spring is very import ant .4. Adj ust t he mult i- funct ion swit ch aft er t he valve adj ust ment .http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/solenoid.htm (3 of 4)2548-12-08 1:33:50AL4 Solenoids5. Cleanliness is absolut ely essent ial when working on t he t ransmission. Technical informat ion bypeugeot logic. com http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/solenoid.htm (4 of 4)2548-12-08 1:33:50Multifunction SwitchAL4 Multifunction Switch FaultDocument created: 22.03.2003Last updaded: --.--.---- Model:All models equipped with an AL4 automatic transmissionSymptoms:Warning lights flashing. (Snow and sport light flashing simultaneously) this is usually accompanied with shift quality related complaints.Fault codes:The following fault codes can be stored in the ECU.1. Automatic transmission control unit. Permanent (intermittent) fault. Multifunction switch open/short circuit.2. Automatic transmission control unit. Permanent (intermittent) fault. Multifunction switch intermediate positionPossible Causes: a. Defectiv Switchb. Switch out of adjustmentc. Poor connectionRectification:A permanent fault usually indicates that the switch is defective and fitting a new part will solve the problem.With an intermittent fault it may be possible that the switch is out of adjustment. The fault can http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/mfswitch.htm (1 of 2)2548-12-08 1:33:59Multifunction Switchbe induced by slowly moving the lever between speeds. With D selected and light pressure applied towards 3 observe the selector indicator on the instruments. If the light at D goes off followed by the warning lights flashing, this means the fault has been triggered. Another way to do this is by moving the selector lever slowly from 3 towards D. This is much more difficult to do. Easy inducement by manipulating the selector lever means, there is a high probability of an incorrect switch adjustment. Adjusting the switch should solve the problem.Should all of the above fail to permanently solve the problem, it will be necessary to do some wiring and connection checking. We like to save this time consuming and tedious task as a last resort. In our experience the most encountered problems are switch defects and adjustments. We opened up a multifunction switch in order to find out what goes wrong. The picture above shows a contact slider with the broken contact tips clearly visible. It appears that the material becomes brittle possibly due to thermal stress. The temperatures on top of the transmission can be quite high and put a high demand on material quality. Technical information bypeugeotlogic.com http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/mfswitch.htm (2 of 2)2548-12-08 1:33:59Solenoid307 Gear Selector Locking SolenoidCreated: 24. 10. 2003Updated: --. --. ---- Model: 307 with AL4 transmission.Subject: How to manually unlock the transmission selector lever.To unlock the selector lever manually do following.Lift up the rubber pad in the storage compartment below the ashtray. Insert a pen, screwdriver or any long object into the square opening on the right of the selector. If you push straight down you should be able to meet the release lever. Hold the release lever down and move the selector out of "P" WARNING!It is easy to be distracted when having to do things that are out of the ordinary.Please remember to keep your foot on the brake whilst performing this operation. http://www.peugeotlogic.com/workshop/wshtml/transmis/al4/solenoid/solenoi1.htm (1 of 2)2548-12-08 1:34:26SolenoidTechnical information bypeugeotlogic.comhttp://www.peugeotlogic.com/workshop/wshtml/transmis/al4/solenoid/solenoi1.htm (2 of 2)2548-12-08 1:34:26